Attachment III - Technical Information

OVERVIEW
This program involves removing two (2) sections of the dash outer insulator from under the vehicle in the area above the forward catalytic converters and installing new adhesive backed insulator pads to the underbody.

SERVICE PROCEDURE

WARNING:
THE VEHICLE EXHAUST SYSTEM MUST BE ALLOWED TO COOL BEFORE PERFORMING THIS REPAIR OR PERSONAL INJURY COULD OCCUR FROM CONTACT WITH THE HOT EXHAUST.

NOTE:
The dash outer insulator material is fastened in place above the transmission and is attached above the right frame just rearward of the front right wheel opening. For this program, it is not necessary to remove the entire piece of insulator, but to cut it along both sides of the transmission tunnel leaving the center section attached to the underbody. The portion that is attached above the right frame can be simply torn away to remove.

1. Raise the vehicle on a hoist.

2. CAUTION: DO NOT cut or damage any wires (H02S, CMS, transmission harness) in the areas above or near the catalytic converters.








Using a sharp razor-type knife, cut the dash outer insulator material from above the catalytic converters as shown in Figures 1 and 2.

^ On the driver side - use the corner shown as a landmark to start or end the cut, then remove the cut piece of insulator. See Figure 1.

^ On the passenger side - follow the transmission tunnel as a guide when making the cut, then pull the insulator to tear it from the right frame.

^ Discard the cut pieces of insulator. See Figure 2.

3. Clean the areas above the catalytic converters using a clean rag to remove any debris, then spray the areas with Brake Clean or equivalent cleaner that will not leave an oily residue and allow the areas to dry completely.

4. CAUTION: DO NOT place the heat shield OVER any part of the remaining dash outer Insulator. Be sure that enough dash outer Insulator material has been Cut away to properly position and install the new insulator pads as outlined.

NOTE:
The adhesive on the new insulator pads is quite strong. Be sure to position it properly before affixing it to the underbody.

Install the insulator pads as follows:








See Figures 3 and 4.

a) Make sure the areas are clean and dry, then peel the backing off the insulator pad.

b) Position the insulator pad directly above the catalytic converter with the lower inside corner of the pad placed directly above the H02S on the rounded corner of the underbody panel.

c) The lower edge of the pad should be parallel to and about 50 mm (2 inches) forward of the underbody stamped gusset.

d) The upper edge of the pad should be almost even with the catalytic converter-to-exhaust manifold flange.

e) Press the pad in place and smooth it down to make sure there is 100% contact to the underbody across the entire pad.

5. Lower and release the vehicle.